I’m working on a saber that is inspired by the more ornate styling/color-scheme of the council member’s hilts. I’ll post some photos of the hilt CAD later, but I have been working on the battery/speaker/crystal chamber for the last few weeks.
It all has to fit through the 0.783" ID of a MHS choke, which is a very tight squeeze for a crystal chamber. First step was machining a tube to slide a 18500 into:
The 24mm speaker is mounted in a holder machined from black Tecanyl:
I wanted the crystal to be lit when the module is removed from the hilt, but unlit any other time (in the hilt). Apparently it is impossible to find NC tactile switches, so I ended up designing a switch that is built into the base of the crystal chamber:
The crystal holder is made from two pieces of brass: a 0.015" thick strip that wraps around the crystal, soldered to a small puck I turned on the lathe. They are nickel-plated to look like one piece:
Everything stacks up in the hilt like this:
Pressing the button on the side of the battery tube disconnects the crystal:
Finally, here it is installed in the lower section of the hilt:
Hopefully over the next few weeks I’ll be able to start on the machining of the emitter, but this is all I’ve gotten done so far. Thanks for reading!